Optimization of a tunable process for rapid production of calcium phosphate microparticles using a droplet-based microfluidic platform

Calcium phosphate (CaP) biomaterials are amongst the most widely used synthetic bone graft substitutes, owing to their chemical similarities to the mineral part of bone matrix and off-the-shelf availability. However, their ability to regenerate bone in critical-sized bone defects has remained inferior to the gold standard autologous bone. Hence, there is a need for methods that can be employed to efficiently produce CaPs with different properties, enabling the screening and consequent fine-tuning of the properties of CaPs towards effective bone regeneration. To this end, we propose the use of droplet microfluidics for rapid production of a variety of CaP microparticles. Particularly, this study aims to optimize the steps of a droplet microfluidic-based production process, including droplet generation, in-droplet CaP synthesis, purification and sintering, in order to obtain a library of CaP microparticles with fine-tuned properties. The results showed that size-controlled, monodisperse water-in-oil microdroplets containing calcium- and phosphate-rich solutions can be produced using a flow-focusing droplet-generator microfluidic chip. We optimized synthesis protocols based on in-droplet mineralization to obtain a range of CaP microparticles without and with inorganic additives. This was achieved by adjusting synthesis parameters, such as precursor concentration, pH value, and aging time, and applying heat treatment. In addition, our results indicated that the synthesis and fabrication parameters of CaPs in this method can alter the microstructure and the degradation behavior of CaPs. Overall, the results highlight the potential of the droplet microfluidic platform for engineering CaP microparticle biomaterials with fine-tuned properties.

Light-Responsive Materials in Droplet Manipulation for Biochemical Applications

Miniaturized droplets, characterized by well-controlled microenvironments and capability for parallel processing, have significantly advanced the studies on enzymatic evolution, molecular diagnostics, and single-cell analysis. However, manipulation of small-sized droplets, including moving, merging, and trapping of the targeted droplets for complex biochemical assays and subsequent analysis, is not trivial and remains technically demanding. Among various techniques, light-driven methods stand out as a promising candidate for droplet manipulation in a facile and flexible manner, given the features of contactless interaction, high spatiotemporal resolution, and biocompatibility. This review therefore compiles an in-depth discussion of the governing mechanisms underpinning light-driven droplet manipulation. Besides, light-responsive materials, representing the core of light-matter interaction and the key character converting light into different forms of energy, are particularly assessed in this review. Recent advancements in light-responsive materials and the most notable applications are comprehensively archived and evaluated. Continuous innovations and rational engineering of light-responsive materials are expected to propel the development of light-driven droplet manipulation, equip droplets with enhanced functionality, and broaden the applications of droplets for biochemical studies and routine biochemical investigations.

Pumpless deterministic lateral displacement separation using a paper capillary wick

Deterministic lateral displacement (DLD) is a passive separation method that separates particles by hydrodynamic size. This label-free method is a promising technique for cell separation because of its high size resolution and insensitivity to flow rate. Development of capillary-driven microfluidic technologies allows microfluidic devices to be operated without any external power for fluid pumping, lowering their total cost and complexity. Herein, we develop and test a DLD-based particle and cell sorting method that is driven entirely by capillary pressure. We show microchip self-filling, flow focusing, flow stability, and capture of separated particles. We achieve separation efficiency of 92% for particle-particle separation and more than 99% efficiency for cell-particle separation. The high performance of driven flow and separation along with simplicity of the operation and setup make it a valuable candidate for point-of-care devices.

Tunable deterministic lateral displacement of particles flowing through thermo-responsive hydrogel micropillar arrays

Deterministic lateral displacement (DLD) is a promising technology that allows for the continuous and the size-based separation of suspended particles at a high resolution through periodically arrayed micropillars. In conventional DLD, the critical diameter (D_c), which determines the migration mode of a particle of a particular size, is fixed by the device geometry. Here, we propose a novel DLD that uses the pillars of a thermo-responsive hydrogel, poly(N-isopropylacrylamide) (PNIPAM) to flexibly tune the D_c value. Upon heating and cooling, the PNIPAM pillars in the aqueous solution shrink and swell because of their hydrophobic-hydrophilic phase transitions as the temperature varies. Using the PNIPAM pillars confined in a poly(dimethylsiloxane) microchannel, we demonstrate continuous switching of particle (7-μm beads) trajectories (displacement or zigzag mode) by adjusting the D_c through temperature control of the device on a Peltier element. Further, we perform on/off operation of the particle separation (7-μm and 2-μm beads) by adjusting the D_c values.

Microfluidic Coupling of Step Emulsification and Deterministic Lateral Displacement for Producing Satellite-Free Droplets and Particles

Step emulsification, which uses a geometry-dependent mechanism for generating uniformly sized droplets, has recently gained considerable attention because of its robustness against flow fluctuations. However, like shear-based droplet generation, step emulsification is susceptible to impurities caused by satellite droplets. Herein, we demonstrate the integration of deterministic lateral displacement (DLD) to separate the main and satellite droplets produced during step emulsification. Step-emulsification nozzles (16 μm deep) in the upstream region of the proposed device were arrayed on the sidewalls of the main channel (91 μm deep). In the downstream region, the DLD micropillars were arrayed periodically with a critical diameter (cut-off value for size-based separation) of 37 μm. When an acrylate monomer and aqueous polyvinyl alcohol solution were infused as the dispersed and continuous phases, respectively, the nozzles produced monodisperse main droplets in the dripping regime, with an average diameter of ~60 μm, coefficient of variation (CV) value below 3%, and satellite droplets of ~3 μm. Upon entering the DLD region near the sidewall, these main and satellite droplets were gradually separated through the pillars based on their sizes. Finally, off-chip photopolymerization yielded monodisperse polymeric microspheres with an average diameter of 55 μm and a CV value of 2.9% (n = 202).

Technologies for Viable Circulating Tumor Cell Isolation

The spread of tumor cells throughout the body by traveling through the bloodstream is a critical step in metastasis, which continues to be the main cause of cancer-related death. The detection and analysis of circulating tumor cells (CTCs) is important for understanding the biology of metastasis and the development of antimetastatic therapy. However, the isolation of CTCs is challenging due to their high heterogeneity and low representation in the bloodstream. Different isolation methods have been suggested, but most of them lead to CTC damage. However, viable CTCs are an effective source for developing preclinical models to perform drug screening and model the metastatic cascade. In this review, we summarize the available literature on methods for isolating viable CTCs based on different properties of cells. Particular attention is paid to the importance of in vitro and in vivo models obtained from CTCs. Finally, we emphasize the current limitations in CTC isolation and suggest potential solutions to overcome them.

High Macromolecular Crowding in Liposomes from Microfluidics

The intracellular environment is crowded with macromolecules that influence biochemical equilibria and biomacromolecule diffusion. The incorporation of such crowding in synthetic cells would be needed to mimic the biochemistry of living cells. However, only a few methods provide crowded artificial cells, moreover providing cells with either heterogeneous size and composition or containing a significant oil fraction. Therefore, a method that generates monodisperse liposomes with minimal oil content and tunable macromolecular crowding using polydimethylsiloxane (PDMS)-based microfluidics is presented. Lipid stabilized water-in-oil-in-water emulsions that are stable for at least several months and with a high macromolecular crowder concentration that can be controlled with the external osmolality are formed. A crucial feature is that the oil phase can be removed using high flow conditions at any point after production, providing the highly crowded liposomes. Genetically encoded macromolecular crowding sensors show that the high level of macromolecular crowding in the emulsions is fully retained throughout the generation of minimal-oil lipid bilayers. This modular and robust platform will serve the study of biochemistry under physiologically relevant crowding conditions.

Deterministic Lateral Displacement Using Hexagonally Arranged, Bottom-Up-Inspired Micropost Arrays

Size-based separation of particles in microfluidic devices can be achieved using arrays of micro- or nanoscale posts using a technique known as deterministic lateral displacement (DLD). To date, DLD arrays have been limited to parallelogram or rotated-square arrangements of posts, with various post shapes having been explored in these two principal arrangements. This work examines a new DLD geometry based on patterning obtainable through self-assembly of single-layer nanospheres, which we call hexagonally arranged triangle (HAT) geometry. Finite element simulations are used to characterize the DLD separation properties of the HAT geometry. The relationship between the array angle, the gap spacing, and the critical diameter for separation is derived for the HAT geometry and expressed in a similar mathematical form as conventional parallelogram and rotated-square DLD arrays. At array angles <7°, HAT structures demonstrate smaller particle sorting capability (smaller critical diameter-to-gap spacing ratio) compared to published experimental results for parallelogram-type DLD arrays with circular posts. Experimental validation of DLD separation confirms the separation ability of the HAT array geometry. It is envisioned that this work will provide the first step toward future implementation of nanoscale DLD arrays fabricated by low-cost, bottom-up self-assembly approaches.

An integrated microfluidic platform to fabricate single-micrometer asymmetric giant unilamellar vesicles (GUVs) using dielectrophoretic separation of microemulsions

We present a microfluidic technique that generates asymmetric giant unilamellar vesicles (GUVs) in the size range of 2-14 μm. In our method, we (i) create water-in-oil emulsions as the precursors to build synthetic vesicles, (ii) deflect the emulsions across two oil streams containing different phospholipids at high throughput to establish an asymmetric architecture in the lipid bilayer membranes, and (iii) direct the water-in-oil emulsions across the oil-water interface of an oscillating oil jet in a co-flowing confined geometry to encapsulate the inner aqueous phase inside a lipid bilayer and complete the fabrication of GUVs. In the first step, we utilize a flow-focusing geometry with precisely controlled pneumatic pressures to form monodisperse water-in-oil emulsions. We observed different regimes in forming water-in-oil multiphase flows by changing the applied pressures and discovered a hysteretic behavior in jet breakup and droplet generation. In the second step of GUV fabrication, an oil stream containing phospholipids carries the emulsions into a separation region where we steer the emulsions across two parallel oil streams using active dielectrophoretic and pinched-flow fractionation separations. We explore the effect of applied DC voltage magnitude and carrier oil stream flow rate on the separation efficiency. We develop an image processing code that measures the degree of mixing between the two oil streams as the water-in-oil emulsions travel across them under dielectrophoretic steering to find the ideal operational conditions. Finally, we utilize an oscillating co-flowing jet to complete the formation of asymmetric giant unilamellar vesicles and transfer them to an aqueous phase. We investigate the effect of flow rates on properties of the co-flowing jet oscillating in the whipping mode (i.e., wavelength and amplitude) and define the phase diagram for the oil-in-water jet. Assays used to probe the lipid bilayer membrane of fabricated GUVs showed that membranes were unilamellar, minimal residual oil remained trapped between the two lipid leaflets, and 83% asymmetry was achieved across the lipid bilayers of GUVs.

Charge-Based Separation of Micro- and Nanoparticles

Deterministic Lateral Displacement (DLD) is a label-free particle sorting method that separates by size continuously and with high resolution. By combining DLD with electric fields (eDLD), we show separation of a variety of nano and micro-sized particles primarily by their zeta potential. Zeta potential is an indicator of electrokinetic charge-the charge corresponding to the electric field at the shear plane-an important property of micro- and nanoparticles in colloidal or separation science. We also demonstrate proof of principle of separation of nanoscale liposomes of different lipid compositions, with strong relevance for biomedicine. We perform careful characterization of relevant experimental conditions necessary to obtain adequate sorting of different particle types. By choosing a combination of frequency and amplitude, sorting can be made sensitive to the particle subgroup of interest. The enhanced displacement effect due to electrokinetics is found to be significant at low frequency and for particles with high zeta potential. The effect appears to scale with the square of the voltage, suggesting that it is associated with either non-linear electrokinetics or dielectrophoresis (DEP). However, since we observe large changes in separation behavior over the frequency range at which DEP forces are expected to remain constant, DEP can be ruled out.

Particle/cell separation using sheath-free deterministic lateral displacement arrays with inertially focused single straight input

This paper proposes microfluidic particle separation by sheath-free deterministic lateral displacement (DLD) with inertial focusing in a single straight input channel. Unlike conventional DLD devices for size-based particle separation, in which sheath streams are used to focus the particles before the solution containing them reaches the DLD arrays, the proposed method uses inertial focusing to align the particles along the middle or the sidewalls of the straight rectangular input channel. The two-stage model of inertial focusing is applied to reduce the length of the side-focusing channel. The proposed method is demonstrated by using it to separate fluorescent polymer particles of diameters 13 and 7 μm, in the process of which the effect of the particle focusing regime on the separation performance is also investigated. Through middle focusing, the method is further used to separate MCF-7 cells (a model of circulating tumor cells (CTCs)) and blood cells, with ∼99.0% capture efficiency achieved.

Deterministic Lateral Displacement-Based Separation of Magnetic Beads and Its Applications of Antibody Recognition

This work presents a magnetic-driven deterministic lateral displacement (m-DLD) microfluidic device. A permanent magnet located at the outlet of the microchannel was used to generate the driving force. Two stages of mirrored round micropillar array were designed for the separation of magnetic beads with three different sizes in turn. The effects of the forcing angle and the inlet width of the micropillar array on the separating efficiency were studied. The m-DLD device with optimal structure parameters shows that the separating efficiencies for the 10 μm, 20 μm and 40 μm magnetic beads are 87%, 89% and 94%, respectively. Furthermore, this m-DLD device was used for antibody recognition and separation among a mixture solution of antibodies. The trajectories of different kinds of magnetic beads coupled with different antigens showed that the m-DLD device could realize a simple and low-cost diagnostic test.

Polymer-Salt Aqueous Two-Phase System (ATPS) Micro-Droplets for Cell Encapsulation

Biosample encapsulation is a critical step in a wide range of biomedical and bioengineering applications. Aqueous two-phase system (ATPS) droplets have been recently introduced and showed a great promise to the biological separation and encapsulation due to their excellent biocompatibility. This study shows for the first time the passive generation of salt-based ATPS microdroplets and their biocompatibility test. We used two ATPS including polymer/polymer (polyethylene glycol (PEG)/dextran (DEX)) and polymer/salt (PEG/Magnesium sulfate) for droplet generation in a flow-focusing geometry. Droplet morphologies and monodispersity in both systems are studied. The PEG/salt system showed an excellent capability of uniform droplet formation with a wide range of sizes (20-60 μm) which makes it a suitable candidate for encapsulation of biological samples. Therefore, we examined the potential application of the PEG/salt system for encapsulating human umbilical vein endothelial cells (HUVECs). A cell viability test was conducted on MgSO4 solutions at various concentrations and our results showed an adequate cell survival. The findings of this research suggest that the polymer/salt ATPS could be a biocompatible all-aqueous platform for cell encapsulation.

A Review on Deterministic Lateral Displacement for Particle Separation and Detection

The separation and detection of particles in suspension are essential for a wide spectrum of applications including medical diagnostics. In this field, microfluidic deterministic lateral displacement (DLD) holds a promise due to the ability of continuous separation of particles by size, shape, deformability, and electrical properties with high resolution. DLD is a passive microfluidic separation technique that has been widely implemented for various bioparticle separations from blood cells to exosomes. DLD techniques have been previously reviewed in 2014. Since then, the field has matured as several physics of DLD have been updated, new phenomena have been discovered, and various designs have been presented to achieve a higher separation performance and throughput. Furthermore, some recent progress has shown new clinical applications and ability to use the DLD arrays as a platform for biomolecules detection. This review provides a thorough discussion on the recent progress in DLD with the topics based on the fundamental studies on DLD models and applications for particle separation and detection. Furthermore, current challenges and potential solutions of DLD are also discussed. We believe that a comprehensive understanding on DLD techniques could significantly contribute toward the advancements in the field for various applications. In particular, the rapid, low-cost, and high-throughput particle separation and detection with DLD have a tremendous impact for point-of-care diagnostics.

Frequency-enhanced transferrin receptor antibody-labelled microfluidic chip (FETAL-Chip) enables efficient enrichment of circulating nucleated red blood cells for non-invasive prenatal diagnosis

Fetal aneuploidy and other chromosomal aberrations affect 9 in 1000 live births. Unlike the invasive diagnosis with high risk of miscarriage, non-invasive prenatal diagnosis (NIPD) sampling from maternal blood becomes a promising way for fetal genetic screening. However, fetal cell-based NIPD has a major challenge due to the small number of fetal cells present in maternal blood. We designed a frequency-enhanced transferrin receptor antibody-labelled microfluidic chip (FETAL-Chip) for efficient enrichment and identification of circulating fetal cells, i.e., circulating nucleated red blood cells (cNRBCs) from maternal blood. The FETAL-Chip can dramatically enhance the interaction of fetal cells with antibody-coated microposts to increase the capture efficiency while minimizing nonspecific adsorption. With the help of immunostaining, we can identify cNRBCs from as little as 2 milliliter maternal blood. Various numbers of cNRBCs were detected from volunteers as early as 7 weeks after conception and throughout the entire pregnancy. Gene analysis was also carried out to confirm the fetal origin of captured cells. With easy, non-invasive and highly efficient enrichment of cNRBCs, the method presented here offers great potential for non-invasive prenatal diagnosis.